Electrolytic deburring apparatus and method

ABSTRACT

Apparatuses and methods for toolless electrolytic deburring are disclosed in which a charged electrolyte stream flows through a hose and nozzle and can be selectively directed at a desired portion of an external or internal surface of a workpiece. The nozzle or the workpiece can be manipulated to vary the electrolytic deburring working gap so as to control the intensity of the electrolytic deburring and the portion of the workpiece that is electrolytically deburred. The electrolytic deburring is preferably performed in an enclosure having a glove which has an electrical contact that can be used to electrically connect the workpiece to the DC power supply anode simply by gripping the workpiece.

FIELD OF THE INVENTION

The present invention relates to apparatuses and methods for thetoolless electrolytic deburring of metal workpieces.

BACKGROUND OF THE INVENTION

Electrochemical surface machining (“ECM machining”) may be used toremove small amounts of metal from the surfaces of metal workpieces. ECMmachining has long been used for deburring, polishing, cleaning,passivating, and stress-relieving the surfaces of metal parts byelectrochemically dissolving away the irregularities at the metalsurface atom-by-atom. For simplicity of expression, these five differentuses will be referred to singly and collectively hereinafter and in theappended claims as “deburring.” The form of ECM machining that is usedfor deburring is sometimes referred to as “electrochemical deburring”and “electrolytic deburring.” The latter term will be used hereinafterand in the appended claims to refer to ECM machining that is used fordeburring.

In general, there are two kinds of conventional electrolytic deburringmethods: (1) conformal tool electrolytic deburring, and (2) toollesselectrolytic deburring. In both, the part of the metal workpiece that isto be deburred is exposed to an electrically conductive solution calledan electrolyte. The workpiece is made to have a positive charge byelectrically connecting it to the anode of a direct current (“DC”)electrical power supply. One or more other pieces of metal are alsoplaced into the electrolyte bath and are made to have a negative chargeby electrically connecting it or them to the cathode of the powersupply. This metal piece or pieces are referred to hereinafter and inthe appended claims singly and collectively as the “working cathode” todistinguish it or them from the cathode of the power supply. When thepower supply is turned on, a DC current flows between the anode and thecathode of the power supply through the workpiece. As the DC currentflows, metal atoms are electrochemically removed from internal andexternal surfaces of the workpieces which are in contact with theelectrolyte. The DC current is densest along the ridges, burrs, andsharp corners of the workpiece surface and so these featureselectrochemically dissolve away faster than does the rest of theworkpiece surface. This preferential dissolution results in thesmoothing of the metal surface, the removal of burrs, and the slightrounding of sharp corners. The electrolyte is flowed across theworkpiece surface or the workpiece is oscillated in order to wash awaythe removed metal and to bring fresh electrolyte in contact with theworkpiece surface to sustain the electrolytic action. Cycle times forelectrolytic deburring generally are between 10 seconds and 3 minutes.

The main differences between the two conventional types of electrolyticdeburring method are: (1) the configuration and placement of the workingcathode, (2) the size of the gap between the workpiece and the bathelectrode, and (3) the kind of electrolyte used. In conformal toolelectrolytic deburring, the working cathode has a shaped surface thatconforms to the desired final shape of the workpiece and must be placedvery near the workpiece so that the workpiece can take on the complementof that shape. A small gap, generally less than 0.03 inches (0.75millimeters), is maintained throughout the electrolytic deburringoperation. The electrolyte is typically a highly conductive, strong saltsolution.

Toolless electrolytic deburring has its foundations in the technologydisclosed in four U.S. patents which were issued to Karl-ImgemarBlomsterberg: U.S. Pat. No. 4,269,677, which issued May 26, 1981; U.S.Pat. No. 4,405,422, which issued Sep. 20, 1983; U.S. Pat. No. 4,411,751,which issued Oct. 25, 1983; and U.S. Pat. No. 5,256,262, which issuedOct. 26, 1993. In toolless electrolytic deburring, the working cathodeneed not conform to that of the desired final shape of the workpiece.Often, the working cathode is a flat plate or plates which are placedsomewhere in the vicinity of the workpiece. A free-standing conductorthat functions like antenna for the cathodic charge is sometimes used toact as a working cathode and may be inserted into a cavity of theworkpiece for internal surface deburring. In toolless electrolyticdeburring, it is not necessary to maintain a constant gap and the gapcan be large, i.e., up to about a foot (30 centimeters). The electrolytehas a relatively higher resistance than that used in conformal toolelectrolytic deburring. The electrolyte is also generally less hazardousand creates less hazardous by-products during the electrolytic deburringprocess than does the conformal tool electrolyte.

Despite its advantages over conformal tool electrolytic deburring,toolless electrolytic deburring has some drawbacks. One is that theworkpiece usually needs to be immersed into a bath of the electrolyte. Asignificantt amount of electrolyte loss may occur when the workpiecesare pulled out of the electrolyte bath. Another drawback is thatfixturing is usually necessary to hold the workpiece in place during theprocess. The fixture also is needed to electrically connect theworkpiece to the power supply anode. The fixtures graduallyelectrochemically dissolve away during use and scratches and othersurface defects on a fixture can locally accelerated the electrochemicaldissolution rate, shortening the fixture's useful lifetime. Anotherdrawback is that while the conventional toolless electrolytic deburringprocess is well-suited to the simultaneous processing of multipleworkpieces in production quantities, the cost of fixturing makes it isless-well suited to the processing of small quantities of workpieces.

More than a dozen years ago, an uncommercialized, abortive effort wasmade to overcome the need to immerse the workpiece in an electrolytebath for toolless electrolytic deburring. A paper by James B.Koroskenyi, titled “Burlytic Deburring—A New Approach in ElectrochemicalDeburring,” Society of Manufacturing Engineers, MR95-228 (1995), pp.1-25, shows a fixture that was intended for use on a drained benchtop toflush electrolyte through workpieces so as to obviate the need ofimmersing the workpieces in an electrolyte bath and to further localizethe deburring activity. However, the paper does not appear to disclosehow the power supply cathode or anode were intended to be electricallyconnected into the electrical circuit necessary to accomplish theelectrolytic deburring of the workpieces. The paper also does notdisclose whether or not the fixture was ever successfully used for itsintended purpose.

SUMMARY OF THE INVENTION

The present invention provides toolless electrolytic deburring methodsand associated apparatuses that overcome at least some of theaforementioned drawbacks of the prior art. In particular, the methodsand apparatuses of the present invention are particularly well-suitedfor toolless electrolytic deburring of individual workpieces, especiallythose which have areas that need more processing than other areas. Thepresent invention makes it possible to toolless electrolytic deburr aworkpiece without immersing it in a bath of electrolyte and without theuse of a conventional working cathode. Moreover, the present inventionallows the gap between its novel working cathode and a workpiece to beselectively varied in order to locally intensify or diminish the degreeof deburring of a selected portion of the workpiece's internal orexternal surface.

The present invention accomplishes these objectives by associating anovel working cathode with a flexible hose and nozzle from which flows astream of electrolyte that can be selectively directed at any desiredportion of the workpiece, including into or through internal cavities ofthe workpiece. The nozzle of the hose can be manipulated to vary the gapbetween the novel working cathode and the workpiece. In some embodimentsof the present invention, the workpiece also can be selectivelymanipulated during the electrolytic deburring process to enable evenmore control over the intensity of the electrolytic deburring and theportion of the workpiece that is electrolytically deburred.

In method embodiments of the present invention, an electrical powersupply capable of selectively supplying DC current is provided for use.Preferably, the power supply is capable of selectively supplying pulsedDC current. The workpiece is electrically connected to the anode of thepower supply. It should be understood that the term “electricallyconnected” is used herein and in the appended claims to mean that theobjects which are described as being electrically connected to oneanother are situated so that an electrical current can flow directly orindirectly from one to the other. A stream of electrolyte is pumpedthrough the flexible hose and exits the hose through a nozzle. Beforeexiting the nozzle, the stream is electrically connected to the cathodeof the power supply. The nozzle is selectively manipulated tocontrollably impinge the stream upon a selected portion of the workpiecesurface. The power supply is operated to flow a DC current between itscathode and its anode and through the workpiece. The process iscontinued until the desired degree of deburring of the workpiece hasbeen achieved.

The present invention also includes apparatuses for performing themethod embodiments. In addition to the aforementioned power supply,flexible hose, and nozzle, the apparatuses include: a reservoircontaining a quantity of the electrolyte; a pump adapted to move theelectrolyte from the reservoir through the nozzle; and electrical leadsfor electrically connecting the electrolyte stream and the workpiece to,respectively, the power supply's cathode and anode during the toollesselectrolytic deburring process. Some embodiments of the presentinvention also include an enclosure having a window through which anoperator can view the workpiece during processing and a glove forreceiving one of the operator's hands. The operator can use the glove tomanipulate the workpiece, the anode lead, and/or the nozzle. Thegripping area of the glove may be electrically connected to the powersupply anode so that the operator can electrically connect the workpieceto the electrical lead by grasping the workpiece in the gripping area ofthe glove. Some embodiments of the present invention further include asecond glove for receiving the operator's other hand. The second glovepermits the operator to manipulate the nozzle and/or the workpiece. Someembodiments of the present invention include a gas jet, e.g., ofcompressed air, for blowing electrolyte off of the workpiece surfacesand cavities after the electrolytic deburring has been completed.

BRIEF DESCRIPTION OF THE DRAWINGS

The criticality of the features and merits of the present invention willbe better understood by reference to the attached drawing. It is to beunderstood, however, that the drawings are designed for the purpose ofillustration only and not as a definition of the limits of the presentinvention.

FIG. 1 is a schematic of an apparatus for toolless electrolyticdeburring a metal workpiece according to an embodiment of the presentinvention.

FIG. 2 is a perspective view of an enclosure that is a part of anapparatus embodiment of the present invention.

FIG. 3 is a perspective view of a portion of a glove from the enclosureshown in FIG. 2.

FIG. 4. is a schematic showing an arrangement of a staging area,enclosure, and post-deburring handling area in accordance with anembodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In this section, some preferred embodiments of the present invention aredescribed in detail sufficient for one skilled in the art to practicethe present invention. It is to be understood, however, that the factthat a limited number of preferred embodiments are described herein doesnot in any way limit the scope of the present invention as set forth inthe appended claims.

Referring to FIG. 1, there is shown a schematic representation of anapparatus 100 for toolless electrolytic deburring of a metal workpiece102 according to an embodiment of the present invention. The apparatus100 comprises a reservoir 104 containing a quantity of electrolyte 106,a pump 108, a flexible hose 110, a collector 112, and an electricalpower supply 114 that is adapted to provide DC current, preferablypulsed DC current. The reservoir 104 is in fluid communication with thepump 108 via a pipe 116. One end of the hose 110 is operably connectedto the pump outlet 118 and the other end is attached to a nozzle 120.The power supply 114 has a cathode 122 and an anode 124. A firstelectrical lead 126 has one end electrically connected to the cathode122 and its other end electrically connected to the nozzle 120. A secondelectrical lead 128 has one end electrically connected to the anode 124and its other end electrically connected to the workpiece 102.

During operation, the power supply 114 provides a DC current between itscathode 122 and its anode 124 through the workpiece 102 in the followingmaimer. The direction of flow of the electrolyte 106 is indicated byarrows, e.g., the arrow 130. The pump 108 draws in electrolyte 106 fromthe reservoir 104 through the pipe 116 and the pump inlet 132. The pump108 forces the electrolyte 106 out through the pump outlet 118, into thehose 110, and out through the nozzle 120 as a stream 134. The stream 134is electrically connected to the cathode 122 by way of the nozzle 120and so has a negative charge as it exits the nozzle 120. The nozzle 120is manipulated to direct the stream 132 at a desired portion of anexterior or interior surface of the workpiece 102. Its impact with theworkpiece 102 breaks up the stream 132 causing the electrolyte 106 toflood across the surface of the workpiece 102 in the vicinity of theimpact area. Since the workpiece 102 is electrically connected to theanode 124, the workpiece is positively charged and metal iselectrochemically removed from the workpiece surface in the vicinity ofthe impact area of the stream 134. The post-impact electrolyte 106flowing off of the workpiece 102 is directed by the collector 112 intothe filter 136. The filter 136 removes the milling debris and othercontaminants from the electrolyte 106 before the electrolyte 106 returnsto the reservoir 104.

Due to its electrical connection to the cathode 122, the nozzle 120 isthe working cathode of the apparatus 100 in this embodiment of thepresent invention. The length of the stream 134 represents the gapdistance between the working cathode and the workpiece 102. By movingthe nozzle 120 or the workpiece 102 closer or farther away from oneanother, the gap distance is changed and so is the intensity of theelectrochemical action at the surface of the workpiece 102. The presentinvention thus permits dynamic control of the rate of metal removalduring the electrolytic deburring process by changing the relativepositions of the nozzle 120 and the workpiece 102 during theelectrolytic deburring process.

By changing the electrolyte flow rate and/or the spray pattern of thestream 134, the intensity of the electrolytic deburring process can befurther controlled. In some embodiments of the present invention, theflow rate of the electrolyte in the stream 134 is adjustable. Theadjustments may be made by controlling the pumping speed of the pump 108or by inserting a variable control valve 138 between the pump outlet 118and the hose 110 or between the reservoir 104 and the pump inlet 132.Preferably, a variable control valve is incorporated into the nozzle 120to permit adjusting both the flow rate and the spray pattern of thestream 134 and to allow controllable focusing of the stream 134 onportions of the surface of the workpiece 102 that are to bepreferentially deburred.

The apparatus 100 also includes a gas nozzle 140 at the end of a gashose 142 which is in fluid communication with a gas source 144. The gasnozzle 140 selectively emits a gas jet 146 and can be selectivelyoperated to blow away residual electrolyte 104 from the surface of theworkpiece 102 at the end of the electrolytic deburring process.

Optionally, a heat exchange unit, e.g., a chiller, may be included intothe apparatus 100 to control the temperature of the electrolyte.

In preferred embodiments of the present invention, the electrolyticdeburring process is conducted in an enclosure which acts to contain thesplashings and overspray of the electrolyte stream. In addition to theworkpiece 102, the enclosure also preferably encloses the flexible hose110, the nozzle 120, the collector 112, the filter 136, the gas hose142, the gas nozzle 140, and at least portions of the first and secondelectrical leads 126, 128. The power supply 114, the pump 108, and theelectrolyte heat exchanger may also be contained within the enclosure,but are more preferably located outside of the enclosure.

Referring to FIG. 2, there is shown an example of such an enclosure,i.e., enclosure 200. Enclosure 200 has a window 202 through which anoperator can view the workpiece 102 as it is being processed. Amagnified inspection area 204 is provided in the window 202 to enablethe operator to closely inspect the workpiece surface. Enclosure 200also has two glove ports 206, 208 to which are attached insulated gloves210, 212 for receiving the operators hands. The operator can use thegloves 210, 212 for manipulating the workpiece 102, the flexible hose110 and the nozzle 120, the first and second electrical leads 126, 128,the gas hose 142, and the gas nozzle 140. The enclosure 200 also has anoutside foot switch 214 by which the operator can control at least oneof the DC current and the electrolyte flow. The enclosure 200 also has afluid-tight, vertically-sliding door 216 and a handle 218 for the takingthe workpiece 102 into and out of the enclosure 200.

In some preferred embodiments of the present invention, the grippingarea of one of the gloves 210, 212 is electrically connected to thesecond electrical lead 128 so that the operator can electrically connectthe workpiece 102 to the anode 124 simply by grasping the workpiece 102.Referring to FIG. 3, there is shown an electrically insulated glove 210having an electrically conductive contact pad 300 attached to its thumb302. The contact pad 300 is electrically connected to the secondelectrical lead 128, which curls around the thumb 302 and runs down thebackside of the glove 210. The contact pad 300 is located in thegrasping area of glove 210 so that the operator can selectivelyelectrically connect the workpiece 102 to the anode 124 simply bygrasping the workpiece 102.

It should be understood that the present invention also contemplatesother means of electrically connecting the workpiece to the anode,whether or not an enclosure is utilized. For example, during processing,the workpiece can be placed upon a conductive work table that iselectrically connected to the anode or the workpiece can be placed intoelectrical connection with a portion of a fixture which is electricallyconnected to the anode. Another alternative, would be to physicallyconnect an electrical lead directly to the workpiece.

In addition to having an enclosure, e.g., enclosure 200, someembodiments of the present invention also have a staging area and/or apost-deburring handling area in operable communication with theenclosure. Referring to FIG. 4, there is shown a schematic depiction ofan enclosure 200 that is in operable communication with both a stagingarea 400 and a post-deburring handling area 402. Vertically-slidingdoors 404, 406, 408, 410 permit a workpiece to be brought into thestaging area 400 and then transferred to the enclosure 200 and fromthere to the post-deburring handling area 402 and then to be removedtherefrom. The staging area 400 may be used for holding one or morepre-cleaned workpieces or it may be used to clean and hold workpiecesthat are to be electrolytic deburred in enclosure 200. Thepost-deburring handling area 402 may be used as an area for washingelectrolyte off of deburred workpieces. The staging area 400 and thepost-deburring handling area 402 are preferably at least partly enclosedand may be portions of the enclosure 200. If enclosed, they preferablyhave means to either directly handle, e.g., glove ports, or remotelyhandle, e.g., robotic arms, the workpieces, but they may be completelyopen, e.g., platforms or worktables.

In the above discussion of the embodiment of the present inventiondepicted in FIG. 1, the nozzle 120 is the effective working cathode forthe electrolytic deburring process. However, other means of providing aworking electrode to impose a negative charge to the electrolyte stream134 are within the contemplation of the present invention. For example,a portion of the flexible hose 110 may be lined with an electricalconductor that is electrically connected to the cathode 122, e.g.,through the first electrical lead 126. Another example is to providewithin the hose 110 or within the nozzle 120 an electrically conductivescreen that the electrolyte passes through or an electrically conductiveelement that protrudes into the electrolyte. In any case, it ispreferred that the outer surfaces of the hose 110 and the nozzle 120 beelectrically insulated to avoid the occurrence of electrical shorts.

Also as discussed above with regard to the embodiment of the presentinvention described in FIG. 1, it is preferred, although not necessary,that the apparatus include a means for providing a gas jet for blowingthe residual electrolyte off of the internal and external surfaces ofthe workpiece. Any suitable gas may be used, but the gas is preferablyfiltered compressed air, nitrogen, argon, or a combination thereof.

The present invention utilizes a DC current power supply, preferably onethat provides pulsed DC current. Such power supplies and the parametersfor their use are well-known to those skilled in the art.

Similarly, the electrolyte that is to be used with embodiments of thepresent invention are known in the art and some are commerciallyavailable. Such a commercially available electrolyte is the CoolPulse®brand process electrolyte which may be obtained from Extrude HoneCorporation, Irwin, Pa. U.S.

In method embodiments of the present invention for toollesselectrolytically deburring a metal workpiece, an electrical power supplycapable of selectively supplying DC current is provided for use. Theworkpiece is electrically connected to the anode of the power supply. Astream of electrolyte is pumped through the flexible hose and exits thehose through a nozzle. Before exiting the nozzle, the stream iselectrically connected to the cathode of the power supply. The nozzle isselectively manipulated to controllably impinge the stream upon theworkpiece or a selected portion of the workpiece. A variable controlvalve may be used to control the flow of the stream from the nozzle orthe spray pattern of the stream. The nozzle or the workpiece may bemoved to vary the distance between the nozzle and the workpiece. Thepower supply is operated to flow a DC current, preferably a pulsed DCcurrent, between its cathode and its anode and through the workpiece.The process is continued until the desired degree of deburring of theworkpiece has been achieved. In some preferred method embodiments of thepresent invention, the process is conducted within an enclosure, such asthe enclosure 200 described above in relation to FIGS. 2-4 and the gloveor gloves of the enclosure are used to manipulate at least one of theworkpiece, an electrical lead that is electrically connected to theanode of the power supply, and the nozzle from which the electrolytestream is emitted. At least one of the gloves may also be used forelectrically connecting the workpiece to the anode by gripping theworkpiece with the gripping area of the glove.

Some method embodiments of the present invention include using a gas jetto blow electrolyte off of a surface of the workpiece. The gas may beone selected from the group consisting of air, nitrogen, argon, orcombinations thereof.

While only a few embodiments of the present invention have been shownand described, it will be obvious to those skilled in the art that manychanges and modifications may be made thereunto without departing fromthe spirit and scope of the present invention as described in thefollowing claims. All patent applications and patents, both foreign anddomestic, and all other publications referenced herein are incorporatedherein in their entireties to the full extent permitted by law.

1. An apparatus for toolless electrolytic deburring a metal workpiece,the apparatus comprising: a) an electrical power supply having an anodeand a cathode, the electrical power supply being adapted to selectivelysupply a DC current; b) a reservoir for containing a quantity of anelectrolyte; c) a flexible hose having a nozzle, the nozzle beingselectively movable with respect to the workpiece during theelectrolytic deburring of the workpiece; d) a pump in fluidcommunication with the hose, the pump adapted to move the electrolytefrom the reservoir through the nozzle; e) a first electrical lead havinga first end electrically connected to the cathode and a second end forelectrically connecting the cathode to the electrolyte; and f) a secondelectrical lead having a first end electrically connected to the anodeand a second end for electrically connecting the anode to the workpiece;wherein during the electrolytic deburring of the workpiece, the pumpmoves a portion of the quantity of the electrolyte from the reservoirthrough the hose and nozzle to form a stream, the first electrical leadsecond end electrically connects the stream to the cathode, the nozzleselectively directs the stream at the workpiece, the stream impinges theworkpiece, the second electrical lead second end electrically connectsthe workpiece to the anode, and the DC current flows between the anodeand the cathode through the workpiece.
 2. The apparatus of claim 1,further comprising a filter adapted to remove contaminants from theelectrolyte.
 3. The apparatus of claim 1, further comprising anenclosure having: a) a window through which an operator can view theworkpiece during the electrolytic deburring of the workpiece; and b) aglove for receiving the operator's first hand, the glove having agripping area and being adapted to permit the operator to manipulateduring the electrolytic deburring of the workpiece at least one selectedfrom the group consisting of the workpiece, the second electrical lead,and the nozzle.
 4. The apparatus of claim 3, wherein the second leadsecond end is electrically connected to the gripping area of the gloveso that the operator can bring the workpiece into electrical connectionwith the second lead second end by gripping the workpiece with thegripping area of the glove.
 5. The apparatus of claim 4, furthercomprising a second glove for receiving the operator's second hand, thesecond glove having a gripping area adapted to permit the operator tomanipulate during the electrolytic deburring of the workpiece at leastone selected from the group consisting of the workpiece, the secondelectrical lead, and the nozzle.
 6. The apparatus of claim 3, furthercomprising at least one of staging area for receiving the workpieceprior to electrolytic deburring and a post-deburring handling area forreceiving the workpiece after the electrolytic deburring of theworkpiece.
 7. The apparatus of claim 6, wherein the enclosure has a workarea for electrolytic deburring the workpiece and at least one doorselectively separating the work area from at least one of the stagingarea and the post-deburring handling area.
 8. The apparatus of claim 3,wherein the enclosure further comprises a magnifying lens adapted toallow the operator to inspect the workpiece.
 9. The apparatus of claim1, further comprising a foot switch for controlling at least oneselected from the the group consisting of the pump and the electricalpower supply.
 10. The apparatus of claim 1, further comprising a valveadapted to control at least one selected from the group consisting ofthe flow of the stream from the nozzle and the spray pattern of thestream from the nozzle.
 11. The apparatus of claim 10, wherein the valveis incorporated into the nozzle.
 12. The apparatus of claim 1, furthercomprising a gas jet, the gas jet being selectively movable with respectto the workpiece and adapted for blowing electrolyte off of a surface ofthe workpiece.
 13. The apparatus of claim 12, wherein the gas jetcomprises at least one selected from the group consisting of air,nitrogen, argon, and combinations thereof.
 14. The apparatus of claim12, wherein the nozzle is adapted to emit the gas jet.
 15. The apparatusof claim 1, wherein the electrical power supply is adapted toselectively supply a pulsed DC current.
 16. A method for toollesselectrolytic deburring a metal workpiece, the method comprising thesteps of: a) providing an electrical power supply having an anode and acathode, the electrical power supply being adapted to selectively supplya DC current; b) electrically connecting the workpiece to the anode; c)pumping an electrolyte stream through a flexible hose to exit a nozzle,wherein the nozzle is attached to the hose and the stream iselectrically connected to the cathode; d) selectively manipulating thenozzle to controllably impinge the stream upon the workpiece; e)operating the power supply to flow a DC current between the anode andthe cathode through the workpiece; and f) continuing steps (c) through(e) until the desired level of electrolytic deburring has been achieved.17. The method of claim 1, further including the step of filtering theelectrolyte to remove contaminants.
 18. The method of claim 16, furthercomprising the step of performing steps (c) through (e) in an enclosure,the enclosure having a) a window through which an operator can view theworkpiece during the performance of steps (c) through (e); and b) aglove for receiving the operator's first hand, the glove having agripping area and being adapted to permit the operator to manipulateduring steps (c) through (e) at least one selected from the groupconsisting of the workpiece, a lead electrically connected to the anode,and the nozzle.
 19. The method of claim 18, further comprising the stepof the operator using the glove to manipulate during steps (d) through(f) at least one selected from the group consisting of the workpiece,the lead, and the nozzle.
 20. The method of claim 18, wherein a portionof the gripping area of the glove is electrically connected to the anodeand step (b) is performed by the operator gripping the workpiece withthe gripping area of the glove.
 21. The method of claim 18, wherein theenclosure further comprises a second glove and further comprising thestep of using the second glove to manipulate during steps (c) through(e) at least one selected from the group consisting of the workpiece andthe nozzle.
 22. The method of claim 16, further comprising the step ofusing a valve to control at least one selected from the group consistingof the flow of the stream from the nozzle and the spray pattern of thestream from the nozzle.
 23. The method of claim 16, wherein step (d)includes moving at least one selected from the group consisting of thenozzle and the workpiece to change the distance between the nozzle andthe workpiece.
 24. The method of claim 16, wherein step (d) includesmoving at least one selected from the group consisting of the nozzle andthe workpiece to impinge the stream upon more than one area of theworkpiece.
 25. The method of claim 16, further comprising the step ofusing a gas jet to blow electrolyte off of a surface of the workpiece.26. The method of claim 25, further comprising the step of selecting thegas jet to comprise at least one selected from the group consisting ofair, nitrogen, argon, and combinations thereof.
 27. The method of claim16, wherein the DC current in step (e) is pulsed.